ALL INDIA SHRI SHIVAJI MEMORIAL SOCIETY’S

COLLEGE OF ENGINEERING PUNE-01.

DEPARTMENT OF MECHANICAL ENGINEERING

MECHANICAL SYSTEM DESIGN

A MINI PROJECT REPORT ON

“DESIGN OF PRESSURE VESSEL”

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 INDEX

Sr No Title Page No

1 Problem statement 3
2 Introduction 3
3 Pressure Vessel code 4
4 Design consideration for pressure vessel 4
5 Thin cylindrical pressure vessel 5
6 Material selection 6
7 Geometry of pressure vessel 7
8 Pressure vessel shell under combined loading 9
9 Class of vessel 13
10 Design of nozzle and opening 13
11 Area method of compensation 14
12 Method of reinforcement 18
13 Design of gasket 18
14 Design of bolt 20
15 Design of flanges 22
16 Do's and Don’ts while using pressure vessel 24
17 Bill of material 25
18 Final Dimension table 25
19 Conclusion 26
20 References 27

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A) PROBLEM STATEMENT:-

Design a pressure vessel used for storage of compressed air for matching of supply and
demand of air and also used for running pneumatic actuators.

The following observations are made-

1) Working pressure = 12 Kgf/cm2

2) Capacity = 210 lit.

Compressor specification- (Reciprocating type V- cylinder compressor)

1) RPM = 925

2) Displacement = 500 lpm

Air receiver specification- (ELGI equipment limited)

Air receiver (Pressure vessel) is horizontal type. The service station has four service point
and each service point has two pneumatic lighteners and two air cleaning guns.

B) INTRODUCTION:-

Several types of equipment’s used in industries have an unfired pressure vessel as a basic
component. Such units are storage vessels, air receivers, etc.

Unfired pressure vessels are all the vessels, pipes & lines for carrying, storing or receiving
steam, gases or liquids at pressure. Vessels are usually spherical or cylindrical with domed
ends. They are provided with opening or nozzle with facilities for making threaded or larger
joints. Various methods are used for supporting the vessel. The operating condition may be
specified as those resulting from the operation during maximum or normal conditions as well
as those that exist during starting up or shutting down or during change in loading ( the latter
being known as transient condition).

The objective of storing liquid or gaseous products is to supply a sufficient balance of each
stock to ensure continuity of operation, secondly to ensure that the product is maintained at
acceptable level. In general storage of liquid or gaseous product is done in large size vessels.

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These consist of unit either completely fabricated in shops or vessels such large that they
must be manufactured at site. Various parts of the vessels are made of size which can be
conveniently transport.

The storage pressure vessel can be considered as a thin cylinder unfired pressure vessel which
stores air at a pressure above the atmospheric pressure.

C) PRESSURE VESSEL CODE:-

A number of national codes which specify inspection, requirements of design, fabrication

inspection & testing of unfired pressure vessels are available. In most countries the traditional
have the force of law and strict adherence to the rule is required. It is therefore desirable that
any design regardless of the method adopted should be checked with standard code. In India,
we usually use IS 2825 : 1969 for design of unfired pressure vessels.

D) DESIGN CONSIDERATION FOR PRESSURE VESSEL:-

1) Design pressure (Pi)-

In unfired press vessel there three terms are commonly related to pressure are-

a) Maximum working pressure- It is the maximum press to which the pressure vessel is
subjected.

b) Design pressure- It is the pressure for which the pressure vessel is designed.

Design pressure = Pi = 1.05 (Maximum working pressure)

c) Hydrostatic test pressure- It is the pressure at which the vessel is tested the pressure
vessel is finally tested by the hydrostatic test before it is put into operation.

Hydrostatic test pressure = 1.3 (Design pressure)

2) Allowable design stress (σall) -

As per IS code & ASME, the allowable stress is based on the ultimate tensile strength with a
factor of safety 3 and 4 respectively.

σall =

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3) Corrosion allowance (c)-

The walls of the pressure vessel are subjected to thinning due to corrosion which reduces the
life of pressure vessel. The corrosion is due to following reason.

1) Chemical attack by reagent on the inner surface of vessel

2) Rusting due to atmosphere air and moisture

3) High temperature oxidation

Every attempt should make to avoid the corrosion. This may not be always possible an
allowance is therefore required to be made by suitable increases in wall thickness to
compensate for thinning due to corrosion.

4) Design temperature-

Strength of metal decreases as temp increases so maximum allowable temperature at which

stress is evaluated should be taken into consideration.

5) Design stress-

It can be obtained by applying FOS to yield strength of material. The FOS allows for any
uncertainty for design metal; the loading quality of material and workmanship. The design
stress based on yield stress or UTS of material at design temp is considered.

E) THIN CYLINDRICAL PRESSURE VESSEL:-

If the ratio of inner diameter of cylinder to its wall thickness is greater than 20, then
cylinder is considered to be thin cylinder,

i.e. > 20 .............(From MSD by R .B. Patil page no.1.2)

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Design of unfired pressure vessel consist of following components-

1) Pressure vessel shell

2) End closures

3) Nozzle and opening

4) Flanged joints

5) Vessel supports

Design of pressure vessel shell of air receiver

Shape of air receiver - Cylindrical

F) MATERIAL SELECTION:-

It is desirable to consider the suitability of different material for construction of pressure

vessel operating under different conditions. Such conditions are temp in range of 600◦ to 200◦
c. Pressure in the range vacuum to as high as 3000kg/cm2 corrosive effect to acid and alkaline
steady or cyclic loading etc, apart from mechanical properties fabrication problems,
commercial availability of material will have to be critically assessed in the final selection of
material.

Material selected for gas storage pressure vessel from IS-2825,1969 code ( page no.119 ) is
austenite stainless steel ( 04Cr19 Ni9 Nb40). It is used for making plates, section, bars
forging and seam line tube.

04Cr19 Ni9 Nb40 consists of

1) Carbon 0.04 %

2) Chromium 19 %

3) Nickel 9 %

4) Niobium 40 %

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 MATERIAL PROPERTIES:-

1) Tensile strength = 55 kgf / mm²

2) Yield strength = 24 kgf / mm²

3) Allowable stress = 16 kgf / mm²

4) Percentage elongation = 28%

Allowable stress at design temp( 65°C ) from IS-2825,1969 the stresses at different
temperature are,

Allowable Stress Temperature

16 kgf / mm² 50°C
14.2 kgf / mm² 100°C

By linear interpolation allowable stress value for 65°C is,

σall = 16 + [( )* ( 14.2 – 16 ) ]

σall= 15.46 kgf / cm2 = 150 N / mm2

Allowable stress at a design temp

65°C= 15.46 kgf / cm² = 150 N / mm2

Pi= 12 bar = 12 * 105 N / m2

Design pressure (Pd) = 1.05 * 1.2 = 1.26 N / mm2

G) GEOMETRY OF PRESSURE VESSEL:-

Capacity of pressure vessel = 210 litre

Volume = 210 litre = 0.21 m³

Assuming length(L) to inner diameter(di) ratio = 3

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 Volume = *di²*L

But, L =3 * di

V = *di²*L* ( 3*di )

0.21 = * di³

Inner diameter(di) ≈ 450 mm

Length of pressure vessel ( L ) = 3 * di

= 3 * 450

L = 1350 mm

Now ,

ts = Thickness of the shell with corrosion allowance, mm

ts= +c

where,

η = Efficiency of longitudinal joints = 0.85

c = Corrosion allowance, mm

di = Inner diameter of cylindrical shell = 450 mm

d = Mean diameter of cylindrical shell = di + t

t = Thickness of the shell without corrosion allowance, mm.

ts = +3

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ts = 6.23 mm

ts = 7 mm

H) Pressure vessel shell under combined loading

In cylindrical pressure vessel shell in addition to pressure the oyher loads are

i) Weight of the vessel with its content

ii) Wind load

iii) Load due to offset piping's

1) Stress in circumferential direction (σt)

σt= = = 71.505 N / mm2

2) Stress in longitudinal direction (σl)

a) Stress in longitudinal direction due to internal pressure

σl1 = =

= 35.43 N / mm2
b) Stress in longitudinal direction due to weight of the vessel and its content in
horizontal pressure vessel or due to wind or seismic load
Figure shows the section modulus about on axis perpendicular to the longitudinal axis of the
vessel is given by,

= 647.533 *103 mm3

Hence bending moment on the horizontal pressure vessel shell

M= {

Where
WT= Total weight of vessel and its content (N) = 15000 N

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H= Depth of head =0.3*L= 405 mm
A= 0.11*L= 149
Putting values in equation M we get,
M= 467.33*103 N.mm
Maximum bending stress
σl3 = =

σl3 = 0.7217 N / mm2

c) σl2 = Stress in longitudinal direction due to weight

σl2 = =

σl2 = 2.629 N / mm2

Total stress in longitudinal direction

σl = σl1 + σl2 + σl3 = 38.78 N / mm2

3) Tensional shear stress due to offset piping (τ)

Torque about the longitudinal axis due to offset piping = (1/2)* Bending moment
= (1/2)*467. 33*1000
=233.665*103 N.mm
J = Polar moment of inertia of vessel cross section about longitudinal axis, mm4

=1.295*106 N.mm

τ= =

τ = 0.180 N / mm2

4) Resultant stress

Maximum resultant stress in vessel shell,

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 σR=
substituting values we get,
σ R = 61.99 N / mm2

As σ R , σ t , σ l < σ all
Hence design is safe.

 Design of end enclosure in pressure vessel

1) Design of torispherical dished head
The torispherical dished head are used for vertical or horizontal pressure vessel in the
pressure range from 0.1 to 0.15 N / mm2.

Thickness of tori-spherical dished head,

th = +C

Where,

Rc= Dish radius or crown radius

ric = Inside corner radius

η = Efficiency of welded joints

b = Inside depth of dish

Kf = Stress magnification factor

= *[3+ ]

for this head, 0.5 * di <Rc ≤ dj

Also, Rc = 0.7 * di = 315 mm

Normally, ric = 0.06 *Rc = 19 mm

substituting the values,

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Kf = 1.767

also, th=5.93

Hence , th= 6 mm

Other dimensions,

b = Rc - Ac

=Rc -

= Rc-

b = 102.44 mm

Straight flange length,

Sf = 3* Th or 20mm ; whichever is larger.

=3* Th = 3* 6 =18 < 20mm

Sf = 20 mm

Volume of fluid contained within ton-spherical head,

Vh = 0.08467 * di3 mm3

Vh =7.715-106 mm3

Storage capacity of pressure vessel

V = volume in shell + volume in heads

V = *di²*L +2{ *di²*sf +Vh}

V= 236.48 *106 mm3

I) CLASS OF VESSEL:

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1. The vessel content is air and also the operation is above -20°C. Hence Class 1 vessel is not
required.
2. The gauge vapour pressure is 12 bar, which is greater than 3.5 bar. Hence Class 3 vessel
also cannot be used.
3. Thus Class 2 Vessel is used.

WELDED JOINT: Double welded butt joint

RADIOGRAPHY: Spot radiography

From the standard chart available efficiency of welded joint is ή=0.85.

J) DESIGN OF NOZZLE AND OPENINGS IN UNFIXED VESSELS:

Openings are provided in the pressure vessel for functional requirement:

1. Inlet and Outlet connections.

2. Drain pipe connections.
3. Pressure gauge connection.
4. Safety gauge connection.
5. Cleaning man holes or flange joint for cleaning.

Nozzle are then formed or welded around these openings. Openings or hole causes
discontinuity in the vessel wall which creates stress concentration the vicinity of the
openings. The stress concentration at the openings can be reduced by providing the
reinforcement in vicinity of the opening. This can be done by:
1.Providing the additional thickness to the vessel wall itself near the nozzle.
2. Use separate reinforcing pad attached to the vessel wall covering an area surrounding the
opening.
3. Providing the additional thickness to nozzle.

The most widely used method for designing reinforcement for a nozzle is area
for area method of compensation.

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J) AREA FOR AREA METHOD OF COMPENSATION:

In this method the area of the material removed is compensated by providing additional area
of material.
1. In the portion of shell as excess thickness.
2. In the portion of nozzle outside the vessel as excess thickness.
3. In the portion of nozzle inside the vessel as excess thickness.
4. In the reinforcement pad (or compensation ring).
From diagram:
Let,

Sr.no Symbol Description

1. dn Inner diameter of nozzle in uncorroded condition
2. dnc Inner diameter of vessel shell
3. tm Minimum required thickness of nozzle wall
4. tn Actual thickness of nozzle wall
5. trs Minimum required thickness of vessel shell
6. ts Actual thickness of vessel shell
7. c Corrosion Allowance
8. Pi Design pressure
9. δall Allowable tensile stress for vessel shell and nozzle
10. ή Efficiency of welded joint in nozzle
11. ήl Efficiency of longitudinal (vessel shell) welded joint.
12. H1 Height of the effective compensation in nozzle wall outside the vessel measured
from outside surface of vessel wall
13. H2 Height of the effective compensation in nozzle wall outside the vessel measured
from inside surface of vessel wall

>>Initially assuming,

di=6.5dn

dn= = 64.23mm ≈ 70mm, therefore dn=70mm

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>>Inner diameter of nozzle in corroded condition:
dnc=dn+2c
=70+2*3
dnc=76mm

>>The minimum required thickness of nozzle wall

tm =

= 0.377 ≈ 1mm

tm=1mm

>> The minimum required thickness of vessel shell

trs =

= 2.25 ≈3mm

trs=3mm

By formula,
H1=

taking tn = 0.76*ts
= 0.76*7

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 = 5.6mm ≈ 6.5mm
tn=6.5mm

H1=

=17mm
H1=17mm

Similarly, H2=

=6.16mm ≈ 8mm
H2=8mm

>>Reinforcement Boundary limit ABCD is such that

AB= 2*dnc
=2*76
AB = 152mm

>>Estimation of compensation:
Area of opening in corroded condition for which compensation is required
Ar=dnc*trs
=76*3
Ar = 228mm²

Area available for compensation (Aa)=

i) The area of excess thickness in the portion of the vessel shell is

A1= dnc(ts-trs-c)
= 76*(7-3-3)
A1=76mm²

ii) Area of the excess thickness in the parts of the nozzle wall outside the vessel shell is
A2=2*H1(tn-trn-c)
=2*17(6.5-1-3)
A2=85mm²

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iii)Area of thickness of nozzle wall thickness inside the vessel shell
A3=2*H2(tn-2c)
=2*8(6.5-2*3)
A3=8mm²

iv)Total area available for compensation(Aa)

Aa=A1+A2+A3
=76+85+8
Aa=169mm²
Ar=228mm² (calculated earlier)

As Aa<Ar, compensation is inadequate and reinforcing pad is required.

Area of reinforcing pad is,

A=Ar-Aa
=228-169
A = 59mm²

dpo=2*dnc
=2*76
dpo=152mm

tp=ts*0.5
tp = 3.5mm

A=(dpo-dp1)*tp
59=(152-dpi)*35
dpi=136mm

Dimensions of reinforcing pad,

dpo=152mm
dpi=136mm
tp=3.5mm

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K) METHODS OF REINFORCEMENT:
It is necessary to place the complete reinforcing material within the boundaries.
These two methods of reinforcement are used:
1. Balance reinforcement.
2. Unbalance reinforcement
We have preferred the Unbalance reinforcement.

Type of attachment of nozzle with pressure vessel shell:

The preferred type of attachment of nozzle with pressure vessel shell is shown in the
figure.This is because, that joint is more efficient and having more strength than other ones.

L) Design of Gasket:
Let,
Go=outer diameter of gasket, mm
Gi=inner diameter of gasket,mm
w=width of gasket

G=Mean diameter of gasket

= Gi+w
bo=Basic gasket seating width
b=effective gasket seating width
= bo, when bo < 6.3mm
= 2.5 when bo ≥ 6.3mm.

δg=gasket seating stress,N/mm²

m=gasket factor
Pi=Design Pressure
σgr= Residual gasket stress under the operating condition, N/mm²

Assumption made in Determination of gasket size,

1.The hydrostatic pressure force extends up to outer diameter of gasket.
2. Elastic deformation of the bolts, gasket and flanges are neglected. The complete

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hydrostatic pressure force is utilized in relieving the gasket seating force that existed prior to
the application of internal pressure.

By standard consideration,
G=12*di
=14*450
G=450mm

Taking σg= gasket seating stress = 15N/mm²

Assuming Gasket factor = m = 2

Gasket seating factor (Fgi) = *[(Go)²-(Gi)²]σg………….a

Hydrostatic Pressure force (Fp)= × × ……………...b

and Residual gasket force(Fgr) = *[(Go)²-(Gi)²]m*Pi…...c

We know that, Fgi-Fp=Fgr………..d

from a,b,c,d we get

Width of gasket,

w= = =

w=15mm

Mean diameter of Gasket,

G= Gi+w
=540+15
G=555mm

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By Empirical relation,
bo=

bo=7.5mm

Effective seating width ,

b=25

=25
=7mm
b=7mm

Hence dimensions of Gasket,

Go=570mm
Gi=540mm
w=15mm
G=555mm
bo=7.8mm

M) DESIGN OF BOLTS:

i)Pre-loads on the bolts:

Total preload on the bolt to induce the stress δg in a gasket is given by,
Wb1=effective area of gasket x Gasket seating Stress
= *G*b*δg
= *555*7*15
Wb1=183.076kN

ii) Total Load on the bolts under operating conditions:

Total Load on the bolts under operating conditions is given by,

Wb2=(load on the bolt due + (Load on the bolt to keep gasket

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 to internal pressure) leak-tight during operation)
= × × + 2* b*G*m*Pi

= *555²*1.2 + 2 *7*555*2*1.26

Wb2=366.33kN

iii) C/s area of each bolt and no of bolts.

Ac= or Ac= (whichever is larger)

From design data book Material for bolt =C45

Sut=550N/mm²
Syt= N/mm²
considering F.O.S=2.5
therefore Allowable tensile stress for bolts under atm conditions= = =110 N/mm²

Allowable tensile stress for bolts under working conditions=100 N/mm²

No of bolts which are to be taken in multiples of 4 and generally

N= 22.5 24

No of bolts is 24

Ac=

Ac=69.344mm²……..1

Similarly

Ac=

Ac=152.64mm²……2
Taking larger of 1 and 2

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Ac=152.64mm²
Ac= ×

152.64= ×

dc=13.94mm

Nominal diameter of bolt is given by

Db=1.19*dc
=1.19*13.14
=16.58mm 18
Db=18mm

Size of bolt
db=M18
N=24

N) DESIGN OF FLANGE:
diameter of bolt pitch circle ia taken as
D=Go + 2*db+12
=570 + 2*18 + 12
D=618mm

Outside Diameter of flange,

Do=D+2*db
618+2*18
Do=654mm

The thickness of flange,

tf = G = +c

where k=0.3+

Wb= Max of Wb1 and Wb2

hg=Radial distance between gasket load reaction and bolt.

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hg= =31.5

hg=31.5mm

Wb=366.336kN
Fp= hydrostatic pressure force N.
= ×

Fp=304822.659N

δall=150N/mm²
putting these values
k=0.3+

k=0.4023

lf=555* +3

lf=35.26mm 40mm

Design of flange
D=618mm
Do=654mm
lf=40mm

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O) Do’s and Don’ts while operating pressure vessel:

DO
 Test the safety relief valve monthly.
 Drain condensate from the tank regularly-daily, if necessary.
 Keep vessel mounted level at all times with vibration protection in place.
 Have the vessel inspected biannually.
 Protect tank from damage caused by vehicle traffic or plant operations.
 Inspect at least weekly for air leaks. If you find an air leak, determine its source (i.e.
line, fitting or crack).
 Report new installations to the State Office of Boiler and Pressure Vessel Safety.

DON'T
 Operate an air tank which is not constructed to meet the requirements of the
American Society of Mechanical Engineers (A.S.M.E.) Code.
 Operate air tank which is not equipped with a functional A.S.M.E. Code safety relief
valve set at or below an established maximum working pressure.
 Mount the vessel rigidly without vibration buffer supports under tank legs.
 Ever operate a vessel without a properly equipped and operating pressure gauge!
 Ever bypass the pressure control switch, or any switches, which control pressure.
 Ever restrict the design function of any safety relief valve-for example; tie down,
paint, block, cap, or remove.
 Make welded repair on air tanks.
 Use plastic pipe for any air discharge line.
 Pile stock up against the tank.

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P) BILL OF MATERIAL:

SR.NO PART NAME MATERIAL QUANTITY

1 BASE C.I 2
2 SHELL LOW ALLOW STEEL 1
3 FLANGE LOW ALLOW STEEL 4
4 GASKET ELASTOMER 2
5 TORISPERICAL HEAD LOW ALLOW STEEL 2
6 BOLT M.S 48
7 NUT M.S 48
8 PROVISION OF INLET NOZZLE STANDARD 1
9 PROVISION OF OUTLET STANDARD 1
NOZZLE
10 DRAIN STANDARD 1

Q) DIMENSION TABLE:

SR
TITLE SYMBOL DIMENSION
NO
1 Inner diameter di 450 mm
2 Length of shell L 1350 mm
3 Thickness of the shell with corrosion allowance ts 7 mm
4 Thickness of the shell without corrosion allowance t 4 mm
5 Thickness of tori-spherical dished head th 6 mm
6 Stress magnification factor kf 1.767
7 Dish radius or crown radius Rc 315 mm
8 Inside corner radius ric 19 mm
9 Inside depth of dish b 102.44 mm
10 Straight flange length Sf 20 mm
11 Volume of fluid contained within ton-spherical head Vh 7.717 m3
12 Storage capacity of pressure vessel V 236.48 m3

AISSMS COE 25
SR.NO DESCRIPTION SYMBOL DIMENSION
1. Inner diameter of nozzle in uncorroded condition dn 70 mm
2. Inner diameter of vessel shell dnc 76 mm
3. Minimum required thickness of nozzle wall tm 1 mm
4. Actual thickness of nozzle wall tn 6.5 mm
5. Minimum required thickness of vessel shell trs 3 mm
7. Corrosion Allowance c 3 mm
8. Design pressure Pi 12 bar
9. Height of the effective compensation in nozzle wall H1 17 mm
outside the vessel measured from outside surface of
vessel wall
10. Height of the effective compensation in nozzle wall H2 8 mm
outside the vessel measured from inside surface of
vessel wall
11. Outer diameter of gasket Go 570 mm
12. Inter diameter of gasket Gi 540 mm
13. Width of gasket w 15mm
14. Effective sealing width b 7 mm
15. Basic gasket sealing width bo 7.5 mm
16. Number of bolts N 24
17. Size of bolt Db 18 mm
18. Pitch Circle Diameter of flange D 618 mm
19. Outer diameter of Flange Do 654 mm
20. Thickness of flange tf 40 mm

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